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Service Manual: Chassis & Mast FBC15N, FBC18N, FBC18LN
Service Manual: Chassis & Mast FBC15N, FBC18N, FBC18LN
Service Manual: Chassis & Mast FBC15N, FBC18N, FBC18LN
99759-7B110
TABLE OF CONTENTS
99759-7B110
ii
TABLE OF CONTENTS
99759-7B110
iii
TABLE OF CONTENTS
Hydraulic Pump
Removal ....................................................................................................................................... 7.12
Installation .................................................................................................................................... 7.13
Disassembly ................................................................................................................................. 7.14
Working Rules and Tips ........................................................................................................... 7.14
Suggestions ............................................................................................................................. 7.16
Inspection after Disassembly ....................................................................................................... 7.18
Body ......................................................................................................................................... 7.18
Mounting Flange Face ............................................................................................................. 7.18
Bushes and Balance Plate....................................................................................................... 7.18
Gears ....................................................................................................................................... 7.18
Reassembly.................................................................................................................................. 7.19
Inspection after Reassembly........................................................................................................ 7.23
Control Valve
Removal ....................................................................................................................................... 7.24
Installation .................................................................................................................................... 7.25
Disassembly ................................................................................................................................. 7.26
Suggestions ................................................................................................................................. 7.27
Reassembly.................................................................................................................................. 7.27
Lift and Tilt Cylinders
Removal
Lift Cylinders ............................................................................................................................ 7.28
Tilt Cylinders ............................................................................................................................ 7.31
Disassembly
Lift Cylinders ............................................................................................................................ 7.33
Tilt Cylinders ............................................................................................................................ 7.34
Inspection after Disassembly ................................................................................................... 7.35
Precautions for Reassembly ........................................................................................................ 7.35
Inspection and Adjustment
Hydraulic Tank.............................................................................................................................. 7.36
Control Valve ................................................................................................................................ 7.37
Lift and Tilt Cylinders.................................................................................................................... 7.40
Adjusting Method ..................................................................................................................... 7.41
Testing ...................................................................................................................................... 7.42
99759-7B110
iv
TABLE OF CONTENTS
Chapter 9: Troubleshooting
Front Axle and Reduction Differential .......................................................................................... 9.1
Brake System ............................................................................................................................... 9.2
Steering System........................................................................................................................... 9.4
Hydraulic System ......................................................................................................................... 9.6
Rear Axle ..................................................................................................................................... 9.8
Mast and Forks ............................................................................................................................ 9.9
99759-7B110
v
TABLE OF CONTENTS
99759-7B110
vi
TABLE OF CONTENTS
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GENERAL INFORMATION
Scope
This service manual deals with all components or systems of the Mitsubishi forklift trucks, except for the
electrical system, which is covered in a separate manual.
8609141A
99759-7B110
1.1
GENERAL INFORMATION
Mast
serial number
Chassis
serial number
Power steering
motor serial number
Traction motor
serial number
Hydraulic motor Nameplate
serial number
8609141
99759-7B110
1.2
GENERAL INFORMATION
Dimensions
8609142
8609143
99759-7B110
1.3
GENERAL INFORMATION
Dimensions Chart
Ref# Truck Model FBC15N, FBC18N FBC18LN FBC20N, FBC25N FBC25EN FBC25LN FBC30N FBC30LN
A Maximum Lift 3320 (130) 3320 (130) 3340 (131) 3340 (131) 3340 (131) 3310 (130) 3045 (119)
B Free Lift 115 (4.5) 115 (4.5) 130 (5.1) 130 (5.1) 130 (5.1) 135 (5.3) 135 (5.3)
D Fork Length 1070 (42) 1070 (42) 1070 (42) 1070 (42) 1070 (42) 1070 (42) 1070 (42)
Tilt Angle
E 5°/6° 5°/6° 5°/6° 5°/6° 5°/6° 5°/6° 5°/6°
(forward/backward)
F Overall Length 3050 (120) 3125 (123) 3155 (124) 3255 (128) 3255 (128) 3325 (131) 3325 (131)
Overall Width
G 945 (37) 970 (38) 1055 (41.5) 1055 (41.5) 1103 (43.5) 1103 (43.5) 1103 (43.5)
(outside of tires)
K Tread (front) 793 (31) 818 (32) 875 (34.5) 875 (34.5) 900 (35.5) 900 (35.5) 900 (35.5)
L Tread (rear) 826 (32.5) 826 (32.5) 900 (35.5) 900 (35.5) 900 (35.5) 900 (35.5) 900 (35.5)
M Wheelbase 1170 (46) 1170 (46) 1280 (50.5) 1380 (54.5) 1380 (54.5) 1380 (54.5) 1380 (54.5)
N Front Overhang 376 (14.8) 376 (14.8) 394 (15.5) 394 (15.5) 394 (15.5) 406 (16) 406 (16)
O Rear Overhang 434 (17.2) 509 (20.2) 411 (16) 411 (16) 411 (16) 469 (18.5) 469 (18.5)
Underclearance
P 118 (4.6) 118 (4.6) 124 (4.9) 124 (4.9) 124 (4.9) 124 (4.9) 124 (4.9)
(at center of wheelbase)
Unit: mm (in.)
99759-7B110
1.4
GENERAL INFORMATION
Units FBC15N FBC18N FBC18LN FBC20N FBC25N FBC25EN FBC25LN FBC30N FBC30LN
Rated Capacity/ kg/mm 1350/600 1600/600 1800/600 1800/600 2275/600 2275/600 2500/600 2725/600 2950/600
Load Center (lb/in.) (3000/24) (3500/24) (4000/24) (4000/24) (5000/24) (5500/24) (5000/24) (6000/24) (6500/24)
Maximum Fork Height mm (in.) 33235 (131) 3340 (131) 3315 (131) 3345 (131)
Performance
36V .38 (75) .36 (71) .34 (67) .32 (63) .28 (55) .25 (49) .23 (45)
Work
Travel Speed 36V km/h 18 (11.2) 17.3 (10.8) 17.4 (10.8) 17.0 (10.6) 17.1 (10.6)
Traveling
Traction Motor 36V 60min. 8.3 (6.2) 12.1 (9.0) 13.7 (10.2)
Output 48V HP(kW) 9.2 (6.8) 14.2 (10.6) 17.2 (12.8)
99759-7B110
1.5
GENERAL INFORMATION
Truck Model
Units FBC15N FBC18N FBC18LN FBC20N FBC25N FBC25EN FBC25LN FBC30N FBC30LN
Mounting
Rear Wheels Center Pivot Type
Wheel Oscillation 3°
Alignment Angle Degrees
Camber 1°
99759-7B110
1.6
GENERAL INFORMATION
Truck Model
Units FBC15N FBC18N FBC18LN FBC20N FBC25N FBC25EN FBC25LN FBC30N FBC30LN
Type Gear
Hydraulic Pump Make Casappa Parker Hydraulics, Inc.
Model KP20–24.5 25R029
99759-7B110
1.7
NOTES
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FRONT AXLE & REDUCTION DIFFERENTIAL
Front Axle
Description
6 8
5
7
4 3 1
2
203658
General Information
The frame supports hold the front axle housing in
such a manner as to allow a limited amount of
rotary motion of the housing, the rotary sliding
surfaces being lubricated with grease.
The cushion tire is press-fitted to the outer ring of
the wheel hub.
99759-7B110
2.1
FRONT AXLE & REDUCTION DIFFERENTIAL
Removal
Front Wheels Suggestions
1. Park the truck on level floor with the parking
! WARNING brake applied, the direction lever in neutral,
Be sure to use the same size and brand the forks lowered, and the key switch off.
tire for replacement. 2. Prepare tools, jacks, and wheel blocks.
3. Block the rear wheels.
4. Loosen the wheel nuts about two turns.
Removal Sequence
2
Wheel nut
1
205952 100902B
1. Wheel Nuts
NOTE
2. Front Wheel
Loosen, but do not remove, the wheel
nuts.
! WARNING
2.2 99759-7B110
FRONT AXLE & REDUCTION DIFFERENTIAL
Method 1 Method 3
Position the jack under the frame and raise the Fasten a hoist to the mast and lift the front end of
truck until the tire clears the floor. the truck as shown.
100828 202778A
! CAUTION
NOTE
After raising the front end, securely support
it by blocks. Service Limit For Cushion Tires
Replace the tire if the height of the solid
rubber portion is 25.4 mm (1 in. or less). For
tire replacement, consult your Mitsubishi
forklift dealer.
25.4 mm
200227 (1 inch)
100880
99759-7B110
2.3
FRONT AXLE & REDUCTION DIFFERENTIAL
Installation
To install, reverse the removal sequence and do 2. Lower the truck until the tire touches the
the following steps. floor. Then tighten the wheel nuts in numbered
sequence shown below, in two or three steps,
to the specified torque.
! CAUTION
1
Use the same size and brand of tire.
6
3
Make sure the clamping surfaces of the
wheel nuts and counterbores in the rim
are free of dirt.
4
5
1. Install the tire and tighten the wheel nuts.
2
Tighten each nut until its tapered portion is
in full-face contact with the counterbore in 205953
the rim.
Tightening Torque For Wheel Nuts
FBC15N - FBC18LN FBC20N - FBC30LN
Wheel Nut
16 kgf•m 38.5 kgf•m
Counterbore
(116 lbf•ft) (278 lbf•ft)
[157 N•m] [378 N•m]
100835A
99759-7B110
2.4
FRONT AXLE & REDUCTION DIFFERENTIAL
Disassembly
6 7
5 205954
Sequence
1. Axle shaft 4. Tapered roller bearing (outer bearing), oil seal,
2. Lock nut, lock washer, oil seal, and tapered and oil deflector
roller bearing (inner bearing) 5. Tapered roller bearing (inner bearing), and
3. Hub & drum assembly [Front wheel hub, brake seal retainer
drum, wheel bolts, drum nuts, and tapered 6. Brake assembly
roller bearing (outer bearing)] 7. Frame support and axle housing
Start By:
1. Remove the mast. (For replacement of the front 3. Support the front end of the truck at both sides
axle housing and disassembly of the differen- with blocks or stands to keep the truck in a
tial, refer to section, MAST AND FORKS.) horizontal position.
2. Jack up the truck. 4. Remove the front wheels.
NOTE
99759-7B110
2.5
FRONT AXLE & REDUCTION DIFFERENTIAL
NOTE
Special Tool
200233
Removing Bearings
The inner race of the tapered roller bearing
remains in the axle housing when the hub is
drawn out. Remove this race together with the
seal retainer with a bearing puller.
203651
99759-7B110
2.6
FRONT AXLE & REDUCTION DIFFERENTIAL
Runout of shaft
99759-7B110
2.7
FRONT AXLE & REDUCTION DIFFERENTIAL
Frame support
O-ring A
205954a
NOTE
200238
99759-7B110
2.8
FRONT AXLE & REDUCTION DIFFERENTIAL
Special tool
203569
FBC20N-
Tool FBC15N-FBC18LN
FBC30LN
99759-7B110
2.9
FRONT AXLE & REDUCTION DIFFERENTIAL
Bar
Spring
balancer
101653
99759-7B110
2.10
FRONT AXLE & REDUCTION DIFFERENTIAL
Reduction Differential
Description
3
4 5 2 1
200240
Sequence
1. Lock plates 4. Reduction gear and differential gear assembly
(spring pins, pinion shafts, differential pinions,
2. Side bearing nuts
differential bevel gear, washers, and differential
3. Differential carrier assembly (lock washers, case)
side bearing caps, and differential carrier)
5. Tapered roller bearings
Start By:
1. Remove the differential carrier from the trans-
mission case.
2. Check the pattern of gears at time of removal.
This step is important when assembly has
been completed and checking pattern of gears
to match.
99759-7B110
2.11
FRONT AXLE & REDUCTION DIFFERENTIAL
Disassembly
Suggestions Removing Bearing Inner Races
1. Before removing the differential carrier from Use a bearing puller to remove the inner races
the transmission case, measure the gear from the differential case.
backlash to aid in obtaining correct backlash
at the time of reassembly.
200242
200247
200241
99759-7B110
2.12
FRONT AXLE & REDUCTION DIFFERENTIAL
A 0.02 to 0.07
Fit of differential (0.0008 to 0.0028)
pinions on spider
B 0.35 (0.0138)
Unit: mm (in.)
A = Assembly Standard B = Repair or service limit
99759-7B110
2.13
FRONT AXLE & REDUCTION DIFFERENTIAL
Reassembly
4 1
3 2
200243
Sequence
1. Tapered roller bearings 3. Spring pin
99759-7B110
2.14
FRONT AXLE & REDUCTION DIFFERENTIAL
Suggestions
Reassembling Differential Pinions Reassembling Differential Case
The thrust washers of the differential gears are to After putting the case assembly in place on the
be used for adjusting the backlash between the carrier, install the bearing caps tentatively by mak-
differential gears and pinions. Measure the back- ing the cap bolts snug tight. The caps are to be
lash and, if it exceeds the limit, replace the thrust secured tight after the bearing preload has been
washers. adjusted.
Unit: mm (in.)
12.8 kgf•m
A = Assembly Standard B = Repair or service limit Tightening torque for
(93 lbf•ft)
bearing cap bolts
[126 N•m]
200244
200241
99759-7B110
2.15
FRONT AXLE & REDUCTION DIFFERENTIAL
200247
Backlash
Increase
Decrease
Decrease
Increase
200246
Increase
Backlash
Decrease
200248
99759-7B110
2.16
FRONT AXLE & REDUCTION DIFFERENTIAL
200250
200249
99759-7B110
2.17
FRONT AXLE & REDUCTION DIFFERENTIAL
203669-2 203669-2A
203669-3 203669-3A
203669-4 203670-4A
203669-5 203670-5A
Repeat the above adjustment until the correct tooth contact is obtained.
99759-7B110
2.18
FRONT AXLE & REDUCTION DIFFERENTIAL
203670-2 203670-2A
203670-3 203670-3A
203670-4 203670-4A
203670-5 203670-5A
Repeat the above adjustment until the correct tooth contact is obtained.
99759-7B110
2.19
NOTES
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99759-7B110
2.20
TABLE OF CONTENTS
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TRANSFER ASSEMBLY
Description
6 Traction motor
5 9 4 6 209002
Main component
1 Transfer case 6 Taper roller bearing
2 Transfer cover 7 Lock nut
3 Input gear (13T) 8 Ball bearing
4 Output gear (48T) 9 Plug (standard) or pulse generator (option)
5 Bevel gear set
99759-7B110
3.1
TRANSFER ASSEMBLY
Disassembly
Start by:
(1) Remove the drain plug on the front axle hous- (3) Remove the traction motor, reduction and dif-
ing to let the oil drain out. ferential assembly and transfer assembly as
(2) Disconnect the connectors of the traction one unit, from the front axle housing.
motor harnesses and pulse generator har- (4) Separate the three assemblies removed in
ness. step (3) from each other.
3 15 Liquid gasket
2
18 1
14
17
Plug (standard)
or 16
Pluse generator (option)
Staked
7
4
6
8 9
13 11 10 12
209002A
Disassembly sequence
1 Bolt 10 Output gear
2 Transfer cover 11 Spacer
3 Side cover with pulse generator, or plug 12 Bearing cup
4 Nut 13 Bearing cup
5 Shim 14 Snap ring
Remove parts 6 and 8 as a unit. Remove parts 15 to 17 as a unit.
6 Bevel pinion shaft 15 Input gear
7 Shim 16 Ball bearing
8 Bearing cone 17 Ball bearing
9 Bearing cone 18 Transfer case
99759-7B110
3.2
TRANSFER ASSEMBLY
NOTE
99759-7B110
3.3
TRANSFER ASSEMBLY
16
209004
99759-7B110
3.4
TRANSFER ASSEMBLY
Reassembly
Follow the disassembly sequence in reverse.
2 4 5
1
17
3
18
16 19
13
10
8 Staked
14
15
6 11 12 7
209002B
Reassembly sequence
1 Transfer case 11 Spacer
Assemble the parts 2 to 4 first, then install the 12 Output gear
assembly into the case 1. 13 Bearing cone
2 Input gear 14 Shim
3 Ball bearing 15 Nut
4 Ball bearing 16 Side cover with pulse generator (option)
5 Snap ring 17 Liquid gasket
Press-fit the parts 6 and 7 into the case 1. 18 Transfer cover
6 Bearing cup 19 Bolt
7 Bearing cup
Assemble the parts 8, 9 and 10.
8 Bevel pinion shaft
9 Shim
10 Bearing cone
99759-7B110
3.5
TRANSFER ASSEMBLY
Axle center
Ball bearings and taper roller bearings can
be fitted onto shafts more easily when
they are warmed in hot oil. However, do
not increase the oil temperature above
120°C (250°F).
209006
NOTE
99759-7B110
3.6
TRANSFER ASSEMBLY
15
(4) Install a new nut 15 on the bevel pinion
shaft 8. Tighten and loosen the nut sev- 13
eral times, each time after rotating the 12
shaft a little, so that the bearing cups 11
209007
and cones settle completely on each
other. Finally, tighten the nut to the
torque shown below. Do not give the
bearings too much preload.
294 ± 20 N·m
Tightening torque of nut 15 (30.0 ± 2.0 kgf·m)
[217 ± 14.5 lbf·ft]
54 to 81 N
Tangential force required to
(5.5 to 8.3 kgf)
start input gear 2 rotating
[12.1 to 18.26 lbf]
4
2
209009
Tightening torque
99759-7B110
3.8
TABLE OF CONTENTS
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REAR AXLE
Rear Axle
Description
3 2
1
7
3
6
B
8609001
99759-7B110
4.1
REAR AXLE
Rear Wheels
Removal Suggestions
1. Park the truck on level floor with the parking
! CAUTION brake applied, the direction lever in neutral,
the forks lowered, and the key switch off.
Use the same size and brand of tire for
replacement. 2. Prepare the tools, parts, jack, and wheel
blocks.
Tools Needed: Spring scale, bearing installer,
and puller.
10 Parts Needed: Lock washer 3; oil seal 7;
cap 1 (when required); bearings 5, 8, 9, and
7 10 (when required); wheel assembly 6.
8 6 A
A
3. Cap 1 is press-fitted to the rim. Pry it off using
a chisel and hammer as shown. Discard the
954 3 2 1
removed cap. Use a new cap when installing a
replacement wheel.
207030
Removal Sequence
1. Cap
2. Outer nut
3. Lock washer
203614
4. Inner nut
5. Inner race bearing 4. Bend down lock washer 3.
99759-7B110
4.2
REAR AXLE
Steering Cylinder
*: Parts contained in seal kit
12
*
11
* 14 13
17 * * 6
▲ ▲
▲
▲ ▲ ▲
9
8
16
10 * 7
▲
▲
▲
▲
▲
•▲ •
▲ ▲ •
5
▲ ▲
2 * 1
15
3 4
207168
99759-7B110
4.3
REAR AXLE
Installation
Blocks
To install, follow the reverse the removal sequence:
1. Using a puller, install bearings (outer) 8 and 9
100393B to the new wheel assembly 6.
2. Install oil seal 7 to the new wheel assembly 6.
10. Remove nut 2, lock washer 3 and nut 4.
11. Remove wheel assembly 6 from the rear
10
axle. Be careful not to cause damage to the
oil seal fitted to the rim. After removing the
7
assembly, raise the counterweight to a position 8 6 A
A
400 to 500 mm (16 to 20 in.) from the floor.
12. Using a puller, remove outer race bearings 8 954 3 2 1
and oil seal 7 from the wheel assembly.
NOTE
207030
Replace the cap and bearings (inner and
outer) if defective.
25.4 mm
(1 inch)
207029
99759-7B110
4.4
REAR AXLE
▲
•
3. Install nut 2, tightening it to 157 N·m (16
Fill with
kgf·m) [116 lbf·ft] torque. Check the hub bearing
grease
preload, making sure it is 2.5 to 6.4 N·m (25 to
65 kgf·cm) [1.8 to 4.7 lbf·ft]. If the preload is cor-
rect, bend lock washer 3.
207024
▲
bar, and measure the tangential force.
FBC15N - FBC20N -
FBC18LN FBC30LN
Tangential 33.1 to 86 26.7 to 69.6
force (3.38 to 8.78) (2.73 to 7.10)
N (kgf) [lbf] [7.4 to 19.3] [6.0 to 15.6]
Reference value
Bar
2.5 to 6.4 N·m
Preload for hub
(25 to 65 kgf·cm)
bearings
[1.8 to 4.7 lbf·ft]
Spring scale
207026
99759-7B110
4.5
REAR AXLE
207024
205436
99759-7B110
4.6
REAR AXLE
Rear Axle
Removal
7
6
2 1
3
203613
Sequence
1. Cap 4. Rim and tire 7. Rear axle assembly
2. Nut and washer 5. Drag link
3. Bearing 6. Bearing support and bolts
Start By:
1. Apply the parking brake and block the front
wheels.
2. Raise the rear end of the truck with a jack and
place wood blocks under the side frames (with
the left and right rear wheels slightly clearing
the floor).
3. A hoist can be used instead of the jack to
raise the rear end (counterweight).
203622
99759-7B110
4.7
REAR AXLE
Suggestions Installation
Removing Rear Axle Assembly To install, reverse the removal sequence and do
the following steps.
! WARNING
Adjusting Bearing Support Clearance
Be sure the pressure in the hydraulic
system is released before any lines or Adjust the longitudinal clearance to 0.8 mm
hoses are disconnected. (0.031 in.) with the thrust washer and tighten the
bolts holding the bearing support to the specified
torque.
1. Put identification marks on the hoses, then
14.8 kgf•m
disconnect them. Tightening torque for
(107 lbf•ft)
2. Support the rear axle at its center with a bearing support bolts
[145 N•m]
garage jack.
3. Loosen and remove the axle mounting bolts.
Clearance:
0.8 mm
(0.031 in.)
200257
203615
FBC20N-FBC30LN 85kg
[187 lb]
99759-7B110
4.8
REAR AXLE
Disassembly
17
16
15
14 2
15 4
17
19
13
11
2
10
9 3
8
6
18
10 1
5
12
207028
Disassembly
Disassembly sequence
1 Taper roller bearing (inner), Retainer 9 Taper roller bearing
2 Tie rod pin, Bolt, Spring washer, Plain 10 Oil seal
washer, Collar, Grease nipple 11 Cover, Retainer
3 Spherical bushing, Ring, Retainer, Dust seal 12 Boot
4 Tie rod 13 Cover
5 Kingpin plate, Shim 14 Clamp, Bolt, Spring washer
6 Kingpin, O-ring 15 Pipe (L.H., R.H.)
Remove parts 7 through 12 as an 16 Steering cylinder [Bolt, Spring washer, Nut]
assembly. 17 Elbow, O-ring
7 Knuckle 18 Stopper bolt, Lock nut
8 O-ring 19 Rear axle housing
99759-7B110
4.9
REAR AXLE
Suggestions
Removing Retainer and Bearing Mark Cylinder End Caps
Use a puller to remove the retainer and inner Mark the cylinder end caps for proper alignment
bearing from the knuckle. before they are disassembled from the cylinder.
Mark
Mark
203618 8609004
99759-7B110
4.10
REAR AXLE
Tires
NOTE
Check the height of the solid rubber portion and, if
If a pin must be replaced, replace its worn down to 25.4 mm (1 in.), replace the tire.
bearing as well.
Kingpins NOTE
Check the kingpins for any surface flaws such as
Replace all tires even if only one tire is
grooving or stepped wear. Inspect the pins for
damaged. If new and used tires are mixed,
cracks at the bearing shoulder.
rapid tire wear will result.
Kingpin Bearings
Examine the rollers and bearing races for groov-
ing, abrasive wear, pitting, bruising, or corrosion.
Replace both the cup and cone of damaged bear-
ings.
Knuckles 25.4 mm
(1 inch)
Inspect the inside of each knuckle for wear or
damage. Be sure to examine for casting cracks.
Check the tie rod pin hole. Examine the wheel nut
threads for damage. 100880
Cylinder Rod
Examine the rod for surface or plating damage.
Inspect the rod for straightness. Examine the pis-
ton for damage. Check the tie rod pin hole for
damage or wear.
99759-7B110
4.11
REAR AXLE
Reassembly
3
2
4
5 17
4 16
3
1
15
11
17
10
9 7
8
13
18
10 19
14
12
207028
Assembly sequence
1 Rear axle housing 11 Cover, retainer
2 Steering cylinder [bolt, spring washer, nut] 12 Boot
3 Elbow, O-ring 13 Kingpin, O-ring, bolt, spring washer
4 Pipe (L.H., R.H.) 14 Kingpin plate, shim, bolt, spring washer
5 Clamp, bolt, spring washer 15 Cover
6 Knuckle 16 Tie rod
7 Spherical bushing, ring, retainer, dust seal 17 Tie rod pin, bolt, spring washer, plain
8 O-ring washer, collar, grease nipple
9 Taper roller bearing 18 Stopper bolt, lock nut
10 Oil seal 19 Retainer, taper roller bearing
99759-7B110
4.12
REAR AXLE
Suggestions
Reassembling Steer Cylinder
1. Replace all seals and O-rings when reassem- 4. Pressure test cylinder reassembly for leaks.
bling the steer cylinder. Lubricate seals and O-
rings lightly with hydraulic fluid.
FBC15N-FBC18LN FBC20N-FBC30LN
2. Assemble wiper seal and U-seal as shown.
107 163
Minimum
(1522) (2320)
test pressure
[10,500] [16,000]
Unit: kgf/cm2 (psi) [kPa]
FBC15N-FBC18LN FBC20N-FBC30LN
Quantity of grease 40cc (2.44 in3) 80 cc (4.88 in3)
99759-7B110
4.13
REAR AXLE
Reassembling Kingpins
1. Install the kingpins and measure the distances 3. Measure the tangential force at point “C”.
“A” on both the left and right kingpins. When the tangential force is larger than the
values shown in the table below, add shims.
When the tangential force is smaller than the
values shown in the table below, remove
shims. Repeat this procedure until the values
in the table are attained.
FBC15N-FBC18LN FBC20N-FBC30LN
1.6 to 2.6 kgf 2.5 to 4.5 kgf
Tangential force (3.5 to 5.7 lb.) (5.5 to 9.9 lb.)
15.7 to 25.5 N 24.5 to 44.1 N
A 8609007
8609009
Shims
Bolt B
8609008
99759-7B110
4.14
REAR AXLE
Reassembling Tie Rods 3. Reassemble rear axle hubs. The inner race of
Replace dust seals. Tighten tie rod pin bolts to the the inner bearing must be driven onto the shaft
specified torque. Grease the joints using the using a special tool as shown below.
grease zerks.
0.7 kgf•m
Tightening torque for bolts (5 lbf•ft)
[6.9 N•m]
Zerk
205022
Dust
seals Rod 4. There is space between the two tapered roller
pin
bearings inside the rear axle hub. Be sure to
bolt
fill this space with grease. Grease the oil seal
8609010 lip groove and roller retainers, too. Do not
overfill the oil seal lip groove as this can
cause leakage.
Reassembling Rear Axle Hub
1. Using Installation Tool #91268-01500 or
#64309-40400 install inner bearing races.
Oil
Using Tool #91268-01400 or 91268-00400 seal
install outer bearing races.
Fill
with
FBC15N-FBC18LN FBC20N-FBC30LN grease
Bearing installer 91268-01500 64309-40400
8609002A
2. Pack bearing cones.
5. Install wheel assembly carefully so as not to
damage the bearing or seal.
10
7
A 8 6 A
9 54 3 2 1
101744
99759-7B110
4.15
REAR AXLE
Bar
8609002B
25 to 65 kgf•cm
Preload for hub bearings
(1.8 to 4.7 lbf•ft)
Tangential Force
[2.5 to 6.4 N•m]
8609002
16 kgf•m
Tightening torque for
(116 lbf•ft)
outer lock nut
[157 N•m]
Bar
Spring scale
101653
9. Install cap 1.
10. Raise the rear end of the truck and remove
the blocking from the side frames.
11. Lower the truck until the rear wheels are on
the floor.
99759-7B110
4.16
REAR AXLE
202800
99759-7B110
4.17
REAR AXLE
STEERING CYLINDER
Disassembly
11
9
A
11
3
*
4
5
2
* 1
6 *
7 7
A * 6
*
2
5
4
*
1 3
8
1
207036
Disassembly sequence
1 Nut, Spring washer, Tie rod 6 Wiper
Remove parts 7 through 12 as assembly. 7 U-seal
2 Cylinder head 8 Cylinder tube
3 O-ring 9 Piston rod
4 Snap ring 10 Guide ring, Piston seal
5 Bushing 11 Stopper ring
NOTE
99759-7B110
4.18
REAR AXLE
Suggestions
Mark Cylinder End Caps
Mark the cylinder end caps for proper alignment
before they are disassembled from the cylinder. Mark
Mark
207035
A: Standard value
Unit: mm (in.) 205439
FBC15N-FBC18LN FBC20N-FBC30LN
Internal diameter of
A 63(2.480) 75(2.953)
cylinder tube 1
External diameter of
A 40(1.575) 50(1.968)
piston rod 2
2 1
207034
99759-7B110
4.19
REAR AXLE
Reassembly
5 5
13
1 2 4 14
16 12
• •
•
15 9
8
6
7 3
10 11 207034
Assembly sequence
1 Piston rod 7 Snap ring 13 Spring washer
2 Piston seal 8 U-seal 14 Nut
3 Guide ring 9 Wiper 15 Pivot joint
4 Cylinder tube 10 O-ring 16 Stopper ring
5 Cylinder head 11 O-ring
6 Bushing 12 Tie rod
Suggestions
1. Replace all seals and O-rings whenever reassem-
bling steer cylinder. Lubricate seals and O-rings
lightly with hydraulic fluid.
2. Assemble wiper seal and U-seal as shown.
3. Align marks on the end caps to marks on the
cylinder body. Tighten nuts.
Wiper U-seal
207042
99759-7B110
4.20
TABLE OF CONTENTS
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BRAKE SYSTEM
Description
Automatic Adjusting Device
205955
General Information
This device adjusts the drum-to-lining clearance
automatically. As the clearance increases due to
lining wear, the lever mechanism of this device
turns the adjusting screw by one notch or tooth to
reposition the shoes closer to the drum. This cor-
responds to 1/24 of one rotation or 15°. In the
course of usage, the adjusting process repeats
itself at long intervals.
99759-7B110
5.1
BRAKE SYSTEM
Master Cylinder
Disassembly
9
8
4 7
10
6
5
*3
91484-37100 FBC15N - FBC18LN
91246-65300 FBC20N - FBC30LN
1
97146-10000A
NOTE
99759-7B110
5.2
BRAKE SYSTEM
99759-7B110
5.3
BRAKE SYSTEM
Service Brakes
Disassembly (FBC15N - FBC18LN)
1
2
16 23 3 24 13 9 9 21
20
19
7
22
6
26
4 10
27 17
15
11
14
18 25
8
12
97146-11800A
Components
1. Service Brake Assembly 15. Spring
2. Wheel cylinder assembly 16. Pin
3. Backing plate 17. Spring
4. Primary shoe and lining assembly 18. Strut
5. Secondary shoe and lining assembly 19. Spring washer
6. Parking Lever 20. Retainer
7. Adjusting screw 21. Bolt with washer
8. Adjusting lever 22. Snap ring
9. Spring 23. Cover
10. Cable guide 24. Parking cable assembly
11. Fitting cable 25. Spring
12. Spring 26. Spring washer
13. Shoe guide plate 27. Bolt
14. Cup
99759-7B110
5.4
BRAKE SYSTEM
2
16 23 10 3 24 13 27 28 29 21
26
9
20
19
7
22
6
31
30 4
14 17
15
14
18 11
12 8 25
97246-10900A
Components
1. Service Brake Assembly 10. Self-locking nut 21. Bolt with washer
2. Wheel cylinder assembly 11. Fitting cable 22. Snap ring
3. Backing plate 12. Spring 23. Cover
4. Primary shoe and lining 13. Shoe guide plate 24. Parking cable assembly
assembly 14. Cup 25. Spring
5. Secondary shoe and lining 15. Spring 26. Spring
assembly
16. Pin 27. Pin
6. Parking Lever
17. Spring 28. Sheave
7. Adjusting screw
18. Strut 29. Plain washer
8. Adjusting lever
19. Spring washer 30. Bolt
9. Spring
20. Retainer 31. Spring washer
99759-7B110
5.5
BRAKE SYSTEM
Start By:
1. Remove the front wheel. 4. Disconnect the brake pipe from the wheel
2. Remove the wheel hub and brake drum. brake assembly.
3. Separate the parking brake lever and cable
at the bottom of the wheel brake.
Suggestions
Removing Return Springs Removing Hold-Down Springs
Use a special tool to remove the return springs. Use a special tool to remove the hold-down springs.
200271 200272
99759-7B110
5.6
BRAKE SYSTEM
203005
200274
99759-7B110
5.7
BRAKE SYSTEM
6 10
A 3
12 1
8 12
13
5
8
4
7
1
11
9
9
14
16
2 Section A-A
15 A
205960
Sequence
1. Backing plate 9. Pin, hold-down spring, and cup
2. Parking brake cable 10. Shoe guide plate
3. Wheel cylinder 11. Fitting cable
4. Parking brake lever 12. Return spring
5. Shoe and primary lining 13. Cable guide
6. Retainer and washer 14. Adjusting lever and adjusting spring
7. Shoe and secondary lining 15. Adjusting screw
8. Strut and anti-rattle spring 16. Return spring
99759-7B110
5.8
BRAKE SYSTEM
A
3 11
6 9
13 1
7
4
8
10
10
12
16
14
Section A-A
15
2 A
205961
Sequence
1. Backing plate 9. Strut and anti-rattle spring
2. Parking brake cable 10. Pin, hold-down spring, and cup
3. Wheel cylinder 11. Shoe guide plate
4. Parking brake lever 12. Fitting cable
5. Shoe and primary lining 13. Return spring
6. Retainer and washer 14. Adjusting lever and adjusting spring
7. Pin, sheave, and washer 15. Adjusting screw
8. Shoe and secondary lining 16. Return spring
99759-7B110
5.9
BRAKE SYSTEM
Suggestions
Installing Wheel Cylinder Greasing
Apply 3 Bond to the mounting face of the wheel Apply a thin coat of the specified brake grease to
cylinder before positioning the cylinder in place. each of the following parts.
Secure it by tightening to the specified torque: 1. Shoe ledges (6 places):
The ledges are the portions of the backing
plate in contact with the shoe.
FBC15N - FBC18LN FBC20N-FBC30LN 2. Anchor pin surface in contact with the shoe
Tightening 0.8 to 1.2 1.8 to 2.7 ends.
torque for (6 to 9) (13 to 20)
wheel cylinder [8 to 12] [18 to 26] Installing Shoes
Unit: kgf•m (lbf•ft) [N•m] Make sure that each push rod of the wheel cylin-
der is snugly fitted to its shoe web.
200275
200276
99759-7B110
5.10
BRAKE SYSTEM
NOTE
99759-7B110
5.11
BRAKE SYSTEM
Wheel Cylinders
Disassembly
10
7
6 12
5 11
9
3
8
2
*
97246-10900B
Sequence
1. Connecting link 8. Spring
2. Boot 9. Cup
3. Piston 10. Piston
4. Piston cup 11. Boot
5. Body 12. Connecting Link
6. Bleeder screw
7. Cap
NOTE
99759-7B110
5.12
BRAKE SYSTEM
200280
Unit: mm (in.)
A = Assembly standard B = Repair or service limit
99759-7B110
5.13
BRAKE SYSTEM
Manual Adjustment
The drum-to-lining clearance can be adjusted by
rotating the adjusting screw with a screwdriver on
to the toothed wheel. The hole through which the
screwdriver tip can be inserted is in the backing
plate.
200281
9 mm
(0.35 inch)
200282
99759-7B110
5.14
BRAKE SYSTEM
Push rod
200285
Brake Test
After completion of necessary adjustments, test
the brake force by operating the truck at a slow
speed of 2.0 km/h (1.2 mph). Test brakes—then
increase speed up to 10 km/h (6.2 mph). Refer to
Manual Adjustment for necessary readjustment.
99759-7B110
5.15
NOTES
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TABLE OF CONTENTS
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STEERING SYSTEM
Steering System
Description
Steering System
6 4
1
8609044
General Information
This steering system is an open-center type,
where the steering fluid is provided by a dedicated
steering pump. The oil is constantly available and
flows through the steer gear and back to the tank
via the mast operating valve.
In this type of steering system, only the small ded-
icated steer pump is pressurized, providing an
efficient, energy-conservation system.
99759-7B110
6.1
STEERING SYSTEM
Steering Gear
Removal
Steering Wheel
8609016
Sequence
1. Nut, washer
2. Wheel
Removal Installation
Use a special tool. To install, follow the reverse of the removal
sequence.
Special Tool Part Number
Wheel puller 91268-10600
Wheel puller
203466A
99759-7B110
6.2
STEERING SYSTEM
Steering Gear
Sequence
1. Column & Kick cover mounting hardware
! WARNING
2. Column & Kick covers
Hydraulic pressure can cause personal
3. Hoses, connectors and o-rings injury. Before any steering system hydraulic
4. Steer column mounting bolts lines or components are disconnected,
make sure all hydraulic pressure is released
5. Steer column in the steering system. Move the steer
6. Steer gear wheels to the left and right, then straight.
NOTE
99759-7B110
6.3
STEERING SYSTEM
Installation
To install, follow the reverse order of the removal
sequence. Tighten bolts to the specified torque
2.9 ± 0.3 kgf•m
Tightening torque for bolts (20.9 ± 2.1 lbf•ft)
[28.4 ± 2.9 N•m]
99759-7B110
6.4
STEERING SYSTEM
Steering Gear
Disassembly
99759-7B110
6.5
STEERING SYSTEM
Steer Pump
Removal
Sequence
1. Motor mounting bracket 3. Motor 5. Pump
2. Motor mounting hardware 4. Pump mounting hardware
Start By:
1. Remove the battery.
2. Remove the acid tray.
3. Disconnect the cables and wires from the
steer pump motor. Mark the wire leads and
cables so they can be correctly reconnected.
4. Disconnect the hydraulic lines from the pump.
99759-7B110
6.8
STEERING SYSTEM
Suggestions Installation
Removing the Motor and Pump Assembly 1. To install, reverse removal sequence.
After disconnecting the steer pump hoses, motor
cables, and harness leads, remove the pump and
motor assembly by removing the motor bracket
mounting hardware where the bracket is bolted to
the frame.
99759-7B110
6.9
STEERING SYSTEM
Disassembly
4
2
6 7
3
5
1
Sequence
1. Cover and mounting bolts 5. Rotor and vanes
2. O-ring 6. Retaining ring
3. Spring and Pressure plate 7. Shaft and bearing
4. Ring and locating pins 8. Body, O-ring, and seal
99759-7B110
6.10
STEERING SYSTEM
Oil Seals
An oil seal, once removed, must not be reused.
After disassembly, examine the oil seal in place
(in the housing) and, if in sound condition, leave it 8609075
in place. When installing a replacement oil seal,
be careful not to score or scratch its lip portion.
Removing the Spring
Lift the spring off the pressure plate.
8609076
99759-7B110
6.11
STEERING SYSTEM
8609077
Retaining
Removing the Rotor and Vanes
Ring
Remove the rotor and the vanes. Take care not to
lose any of the vanes.
8609080
8609078
8609079
99759-7B110
6.12
STEERING SYSTEM
Removing the Shaft and Bearing Removing the Seal and O-ring
1. Tap the end of the shaft very lightly to remove 1. Examine the shaft seal in place in the housing.
it from the pump body. Take extreme care not If it is in sound condition, do not attempt to
to damage the end of the shaft. remove it. Instead, use it as part of the rebuilt
2. Remove the external retaining ring from the unit. If there is any damage to the seal,
shaft to allow removal of the bearing. Tap the remove it and do not reuse it.
end of the shaft very lightly to separate the 2. Remove the O-ring from the slot in the body.
bearing from the shaft. Take extreme care not
to damage the end of the shaft.
8609082
8609081
Inspection after Disassembly
1. Check all mating surfaces. Replace any parts
that have scratches or burrs that could cause
leaks.
2. Clean all metal parts in clean solvent. Blow
dry with air. Do not wipe dry with cloth or
paper towels because lint or other matter can
get into the hydraulic system and cause dam-
age. Do not use a coarse grit or try to file or
grind these parts.
99759-7B110
6.13
STEERING SYSTEM
Reassembly
5
7
8
8609083
Sequence
1. Body and seal 5. Rotor and vanes
2. Shaft and bearing 6. Pressure plate
3. Retaining ring 7. Spring
4. Ring 8. Cover
99759-7B110
6.14
STEERING SYSTEM
8609084
Retaining
ring
8609086
99759-7B110
6.15
STEERING SYSTEM
8609089
8609087
Reassembling the Spring
Slip the spring over the spring seat of the pres-
Reassembling the Rotor and Vanes
sure plate.
Slip the rotor over the splined portion of the shaft.
Insert a vane in each of the slots in the rotor.
8609090
8609088
99759-7B110
6.16
STEERING SYSTEM
8609091
99759-7B110
6.17
NOTES
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TABLE OF CONTENTS
Hydraulic System
Description
Schematic for Trucks
1. Hydraulic tank 4. Steer gear 7. Down safety valve 10. Steering cylinder
2. Hydraulic lift pump 5. Main control valve 8. Lift cylinder
3. Steer pump 6. Flow regulator valve 9. Tilt cylinder
General Information
The hydraulic pump draws oil from the oil tank
and delivers it to the main control valve, which dis-
penses it for lift and tilt functions.
The steer gear and steer pump are covered in the
STEERING SYSTEM section and the steering
cylinder is covered in the REAR AXLE section.
99759-7B110
7.1
HYDRAULIC SYSTEM
Hydraulic Tank
1
6 5
4
3 8609093
General Information
The tank contains internal filtering means including
a strainer on the suction line and a filter on the
return line.
The lift cylinder return pipe allows the cylinders to
draw fluid when they retract, providing the bore
walls with oil which inhibits corrosion.
99759-7B110
7.5
HYDRAULIC SYSTEM
Hydraulic Pump
8609094A
General Information
This gear pump is capable of developing very high
pressure on its discharge side. A special arrange-
ment is incorporated in the pump construction for
the purpose of keeping the side clearances mini-
mized between bushings on the one side and
pump gears on the other. Note, in illustration
203585 (page 7.6), that discharge pressure is
applied to the back of each bushing through inter-
nal oilways.
99759-7B110
7.6
HYDRAULIC SYSTEM
Drive Gear
203585
Discharge side
200333
99759-7B110
7.7
HYDRAULIC SYSTEM
Control Valve
9 8 7
10
14
2 6
3 6
11
12 13
Sequence
1. Inlet / Unloader Spool 8. From Hydraulic Pump
2. Tilt Spool 9. To Tank
3. Auxiliary Spool 10. Main Relief Valve, Auxiliary Valve (back)
4. Auxiliary Attachment Spool 11. Auxiliary Relief Valve (front)
5. Outlet Spool 12. Tie bolt
6. Flow Control Screws 13. Nut
7. Lift Port 14. Switches
General Information
The control valve consists of three valve blocks, all
spool-type. The spools are finished by lapping for
their respective blocks and their combination
should not be changed. The lift valve assembly has
a built-in load check valve. The tilt valve spool has
a built-in tilt lock valve. The attachment valve
assembly has a built-in overload relief valve.
99759-7B110
7.8
HYDRAULIC SYSTEM
200345
205979
General Information
The left and right lift cylinders are single-acting
type.
The left and right tilt cylinders are double-acting
type. The piston rod carries a screw-on socket.
The socket is repositioned as necessary by turn-
ing when the cylinder is connected to the outer
mast. This feature allows the tilt cylinders to move
in unison.
The tilt angle is increased or decreased with the
spacer and shim of each cylinder.
99759-7B110
7.9
HYDRAULIC SYSTEM
Burst
General Information
The down safety valve is built in the oil pipe joint at
the bottom end of the lift cylinder. This valve is
internally provided with an orifice to prevent shock
when the valve is closed. In the valve having no ori-
fice, the oil leaks around the valve to prevent
shock.
Valve Types
Down safety valves are available in six types differ- a
ing in terms of shutoff flow and identified by the
number punched on the flat (indicated as “a” on
illustration 201731A). The numbers are: 50, 70, 90,
100, 120, and 150. No. 90 and No. 120 valves each
come in two kinds differing in screw thread size. a
FBC15N -
FBC18LN 70 90 70 90 70 Top View: • Dual-stage panoramic lift cylinder
FBC20N - • Dual-stage full free-lift panoramic,
FBC25EN 70 120 70 120 70
FBC25LN - 1st and 2nd cylinders
FBC30LN 90 90 120 120 90 • Triple-stage full free-lift panoramic,
2nd lift cylinder
Bottom View: • Triple-stage full free-lift panoramic
1st lift cylinder
99759-7B110
7.10
HYDRAULIC SYSTEM
! WARNING
99759-7B110
7.11
HYDRAULIC SYSTEM
Hydraulic Pump
Removal
Sequence
1. Hardware
2. Pump
Start By:
1. Disconnect the battery from the truck. 5. Secure the motor from above with a crane,
hoist, or other adequate device, or support it
2. Disconnect the hoses attached to the pump
at its center with a garage jack.
fittings.
6. Remove the motor and pump assembly from
3. Disconnect the power cables and wire leads
the truck.
from the pump motor.
7. Remove the hydraulic fittings from the pump.
4. Raise the truck enough to allow the pump and
motor assembly to be removed from below the
truck. Make sure that the truck is stable and
secure in the raised position.
99759-7B110
7.12
HYDRAULIC SYSTEM
Installation
1. To install, follow the reverse sequence of the
disassembly procedure. Before installing
hydraulic fittings in the pump, inspect all
O-rings for damage or aging and replace
them as required.
2. Tighten hose to the following specifications.
FBC15N-FBC18LN FBC20N-FBC30LN
99759-7B110
7.13
HYDRAULIC SYSTEM
Disassembly
Standard Pump (1 ton)
5
3
1
4
7
9
6
Sequence
1. End cover 4. Shaft seal and retainer ring 7. Drive shaft
2. O-ring, bush seal, and 5. O-ring, bush seal, and 8. Gear pack
back-up seal back-up seal 9. Body and rear bushes
3. Flange 6. Front bushes
99759-7B110
7.14
HYDRAULIC SYSTEM
Disassembly
Standard Pump (2/3.3 ton)
1 5
9
4
7
6
Sequence
1. End cover 4. Shaft seal and retainer ring 7. Drive shaft
2. O-ring, bush seal, and 5. O-ring, bush seal, and 8. Gear pack
back-up seal back-up seal 9. Body and rear bushes
3. Flange 6. Front bushes
Start By:
Externally clean the pump to make sure that it is free
of all matter that may contaminate the pump parts
during disassembly, inspection, or reassembly.
99759-7B110
7.15
HYDRAULIC SYSTEM
8609101
8609100
8609102
99759-7B110
7.16
HYDRAULIC SYSTEM
8609103
8609104
99759-7B110
7.17
HYDRAULIC SYSTEM
Inspection after Disassembly 3. The bush bearing liners are acceptable if they
are not scored or do not show other damage.
Body The general outside area of the bush should
not show any prominent signs of wear.
1. Inspect the body bore cut-in where gears wipe
into the body. Gears
2. The body can only be reused if the cut-in is
1. The gear side faces should be examined for
bright and polished in appearance and the
bushing or scoring. Often operation on con-
depth does not exceed .08 mm.
taminated fluid shows scoring between the
3. The body should be replaced if the surface is root of the gear and the journal, which leaves
scored, has a matte appearance, or shows a wear step. If a wear step can be felt, coinci-
signs that the tips of the gears have dug in dental with the root diameter, by drawing a
and torn away the surface material. sharp-pointed tool across the surface from the
4. The body should be inspected to ensure that journal outward towards the tip of the gear,
there is no superficial damage which may then the gear must be replaced.
adversely affect performance or sealing. Pay 2. The gear teeth should be carefully examined
particular attention to the port threads and to ensure that there are no signs of bruising or
body O-ring seal recesses. pitting.
3. The journal bearing surfaces should be com-
Mounting Flange Face
pletely free from scoring or bruising. The sur-
1. The inner surfaces should be inspected to face should be highly polished and smooth to
ensure that there is no unusual wear or scoring the touch.
in the regions where the body O-rings and bush
4. Examine the area where the shaft seal lips run
seals contact, which could result in external leakage.
on the drive shaft. This shows up as polished
2. Check the shaft seal recess for scoring or dam- ring or rings. If a noticeable groove can be felt,
age that could result in oil leakage around the or if there is scoring, the shaft should be
outer diameter of the shaft seal. A replacement replaced.
shaft seal can be refitted with Loctite hydraulic
5. Examine drive keyway in driveshaft journal
sealant to overcome slight damage in this area.
extension to ensure it is not damaged or
chipped.
Bushes and Balance Plate
6. If the driveshaft is not damaged from the drive
1. The side faces which abut the gears should be coupling and the gears have not been harmed
perfectly flat and show no signs of scoring. as described above, then the gears can be
Characteristically there are bright polished reused. If the gears are damaged, they must
areas on this surface caused by loading be replaced as a matched set.
against the gear side faces. This is often more
pronounced on the low-pressure side. These 7. As a matter of good practice, when pumps
should be replaced if there is any general have been dismantled, all the seals should be
scoring or fine scoring with a matte appearance replaced.
or tearing of the surface material.
2. Often, the tips of the opposing gears have
wiped an overlap in a half-moon shape. There
must be no noticeable wear step as it is criti-
cal that the bush side face and balance plate
are completely flat to the gear side face.
99759-7B110
7.18
HYDRAULIC SYSTEM
Reassembly
Trucks with Standard Hydraulic Pump
5
3
1
4
7
9
6
Sequence
1. End cover 4. Shaft seal and retainer ring 7. Drive shaft
2. O-ring, bush seal, and 5. O-ring, bush seal, and 8. Gear pack
back-up seal back-up seal 9. Body and rear bushes
3. Flange 6. Front bushes
Start By:
Ensure that all parts are perfectly clean. Lubricate
the bushes and gears with clean hydraulic fluid.
Ensure that the O-ring recess and end faces of the
body remain dry. This will assist the assembly of
the components with the body bores.
99759-7B110
7.19
HYDRAULIC SYSTEM
Cusp
Removal
Inlet 8609109
Position of
driveshaft
Counterclockwise Rotation
8609108
99759-7B110
7.20
HYDRAULIC SYSTEM
8609112
Premium pump configuration 1. Fit a new shaft seal into the recess in the
mounting flange with the “garter” spring facing
into the pump.
2. If the seal recess was scored, then Loctite
hydraulic sealant must be applied to the outer
diameter of the seal.
3. Apply a coat of high-melting-point grease to
the shaft seal lips.
4. Reinstall the retaining ring. Ensure that it is
located in its groove.
8609102
8609111
99759-7B110
7.21
HYDRAULIC SYSTEM
End
cover
8609115A
8609113
Reassembling the Rear O-ring and Seals FBC15N - FBC18LN FBC20N - FBC30LN
1. Hold the whole unit together and carefully turn 4.7 to 5.2 kgf•m 9.0 to 10.4 kgf•m
it over. Ensure that it is supported on the Tightening torque (34 to 38 lbf•ft) (65 to 75 lbf•ft)
mounting flange, not the driveshaft. for bolts [46 to 51 N•m] [88 to 102 N•m]
2. Remove the end cover and install a new O-
ring, bush seal, and backup seal.
NOTE
8609114
99759-7B110
7.22
HYDRAULIC SYSTEM
Pressure
Test gauge
unit Micronic Variable
filter restrictor
Flow
Strainer Relief meter
Tank
valve
8609116
99759-7B110
7.23
HYDRAULIC SYSTEM
99759-7B110
7.24
HYDRAULIC SYSTEM
99759-7B110
7.25
HYDRAULIC SYSTEM
Disassembly
99759-7B110
7.26
HYDRAULIC SYSTEM
Suggestions Reassembly
Main Relief Valve Before Reassembly:
1. Wash all parts except for O-rings with solvent.
NOTE
2. Apply hydraulic oil to O-rings when installing
To remove main relief valve for cleaning or them.
inspection, loosen its plug. Loosening the 3. Make sure that each spool moves freely.
lock nut will disturb the pressure setting.
5 4
1
207068
Sequence
1. Hose guard 4. Cylinder clamp (cushion, collar, and shims)
2. High-pressure hose 5. Lift cylinder and bracket
3. Set bolt and shims
99759-7B110
7.28
HYDRAULIC SYSTEM
Suggestions
1. Removing hose guard:
With the lift bracket raised to the maximum
height, remove each hose guard from the front
side of the mast.
! CAUTION
Be careful not to touch the lift control
lever.
Right-hand cylinder
Left-hand cylinder
204933
99759-7B110
7.29
HYDRAULIC SYSTEM
204935
204934
NOTE Installation
The rod end of either lift cylinder is shim-
Lift Cylinders
adjusted to eliminate the difference in To install, reverse the removal sequence and do
stroke between the cylinders. Before the following steps.
removing the stopper bolts, make a record 1. Extend and retract the lift cylinders several
of the number of shims and the cylinder to times under no-load conditions to expel air
which the shims are fitted. from the cylinder circuits and to make sure the
cylinders move smoothly.
2. Place wood blocks under the inner mast and 2. Check the oil level in the hydraulic tank with
detach the sling. Use blocks strong enough to the oil level gauge.
support the mast. 3. Check that the lift height is correct.
4. After the lift cylinders or piston rods have been
replaced, check for difference in stroke
between the two cylinders (refer to MAST
AND FORKS).
202983
99759-7B110
7.30
HYDRAULIC SYSTEM
Removal
Tilt Cylinders
3
1
206883
Sequence
1. Tilt socket pin (spacer) 3. Cylinder pin (spacer)
2. Rubber hose (O-ring) 4. Tilt cylinder
Start By:
1. Lower the forks all the way and tilt the mast
fully forward.
2. Hitch lifting slings to the top crossmember of
the outer mast by passing them through the
round holes. Take up the weight of the mast
with a hoist.
Suggestions
1. Retracting piston rod:
207085
Remove tilt cylinder pin (item 1), and retract
the piston rod all the way.
2. Disconnecting hoses:
Disconnect hoses (item 2) from the cylinder at
the connectors. Use a container to catch oil
from flowing out of the cylinder. Attach caps to
the connectors of the cylinder to protect the
threads of the connectors and to prevent oil
from flowing out of the cylinder when the cylin-
der is removed.
99759-7B110
7.31
HYDRAULIC SYSTEM
Suggestions
Removing Tilt Socket
Later Version
! WARNING
1
4
2 3 206883
1. Rubber hose
2. Tilt socket pin, bolt, washer
3. Tilt cylinder pin, bolt, washer
4. Tilt cylinder
NOTE
99759-7B110
7.32
HYDRAULIC SYSTEM
Disassembly
Lift Cylinders
5
4
204948
Sequence
1. Bracket assembly 4. Piston rod, snap ring, holder, U-ring, nylon
heel, and piston ring
2. Holder, wiper ring, U-ring and O-ring
5. Cylinder tube
3. Bushing and bearing
Suggestions
Removing Piston Rod
Draw the piston rod out gently, taking care not to
damage the sealing members fitted to the piston.
200349
99759-7B110
7.33
HYDRAULIC SYSTEM
Disassembly
Tilt Cylinders
✱ Parts contained in seal kit
3
✱
1 ✱
✱
✱
1
207050
Sequence
1. Tilt socket, bushing, bolt, washer, nut, and 3. Piston rod, piston seal, and nut
grease fitting
4. Cylinder tube and bushing
2. Bushing, O-ring, dust seal, packing and
buffer ring
NOTE
Suggestions
Removing Bushing
1. Wrap the cylinder with a wad of cloth and hold
it in a vise. Using a wrench, remove the bush-
ing from the cylinder.
2. When removing the bushing from the piston
rod, be careful not to rub the buffer ring, pack-
ing, etc., against the threads of the piston rod.
200351
99759-7B110
7.34
HYDRAULIC SYSTEM
200352
200353
99759-7B110
7.35
HYDRAULIC SYSTEM
Suction Strainer
! WARNING
Check the suction strainer for clogging or damage.
Remove the hydraulic tank filler cap only
after the truck has been stopped and the Return Filter
fill cap is cool enough to remove with your
bare hand. Check the return filter for clogging or damage.
99759-7B110
7.36
HYDRAULIC SYSTEM
Control Valve
External Leakage
1. Check for oil leaks from the joint between 2. Quickly disconnect the oil return hose and
adjacent valve housings sealed by O-ring. start collecting the oil coming out of the valve
2. Check for oil leaks from the scrapers sealed from the oil return port A.
by O-rings.
3. Check for oil leaks from the screw
connections.
Internal Leakage
It is not practical to check the control valve alone
for internal leakage. The correct way to check the
control valve in place under normal operating con-
ditions follows.
The internal leakage to be checked includes leak-
age occurring at the lift spool, tilt spool, tilt lock A
valve, and check valves.
[Test oil temperature: approx. 50°C (122°F)]
Amount of oil collected 500 cc (30.5 cu. in.)
1. Pick up a load equal to the rated capacity. Lift for 15 minutes maximum
it approximately 1 meter (3 ft) high. Tilt the
mast forward 3° - 4° and turn off key.
3. If the tilt cylinders or lift cylinders drift (the mast
tilts forward or the fork lowers) excessively even
3° - 4°
though the amount of oil collected in 15 min-
utes is less than 500 cc (30.5 cu. in.), measure
the internal leakage of each cylinder. (The
measurement is the assembly standard and not
the service limit.)
approx.
1 meter
(3 feet)
203521A
99759-7B110
7.37
HYDRAULIC SYSTEM
B
A
C
99759-7B110
7.38
HYDRAULIC SYSTEM
Basic Hydraulic Switch Adjustments Install switch on Tilt spool or Auxiliary spool per
Install switch on Lift spool per Photo 1. Adjust and Photo 3 centered on spool lobe. Adjust and torque
torque bolts on switches to 7 ± 1 in-lbs [0.79 N•m bolts on switches to 7 ± 1 in-lbs [0.79 N•m ± 0.11
± 0.11 N•m] (0.08 kgf•m ± 0.01 kgf•m). N•m] (0.08 kgf•m ± 0.01 kgf•m).
Photo 1 Photo 3
Switch 2
Switch has
to activate
before
reaching
B
point B (the
top of the
cam).
Switch 2
Photo 2
99759-7B110
7.39
HYDRAULIC SYSTEM
207054
99759-7B110
7.40
HYDRAULIC SYSTEM
Adjusting Method
1. Raise the inner mast, place blocks under the 3. Extend the piston rod and tighten the cylinder
right and left sides of the mast, and lower the stopper bolt. Remove the blocks from under
mast until it rests on the blocks. the inner mast.
4. Slowly lower the inner mast all the way to make
sure that the piston rods move smoothly.
202983
Stopper bolt
Shims
200365
NOTE
99759-7B110
7.41
HYDRAULIC SYSTEM
Testing
Lift Cylinder Drift Test Tilt Cylinder Drift Test
1. Pick up a load equal to the rated value, tilt the 1. Pick up a load equal to the rated value, tilt the
mast to the vertical position, raise the forks 1 mast to the vertical position, raise the forks
to 1.5 m (3.3 to 4.9 ft) and stop the truck. about 50 cm (20 in.) and stop the truck.
2. Scribe a line on the mast column and measure 2. Measure the drift extension of the tilt cylinder
the drift of the lift cylinder (drop for 15 minutes) for (extension) 15 minutes.
206891 207056
FBC15N - FBC25EN FBC25LN - FBC30LN FBC15N - FBC18LN FBC20N - FBC25EN FBC25LN - FBC30LN
Lift cylinder drift 50 (2.0) 40 (1.6) Tilt cylinder drift 22 (0.9) 20 (0.8) 15 (0.6)
(rated load) maximum (rated load) maximum
Unit: mm (in.)/15 min Unit: mm (in.)/15 min
Piping
1. Check each hydraulic circuit for leaks.
2. Check to make sure that each hose is free
from twisting or excessive loops.
99759-7B110
7.42
TABLE OF CONTENTS
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
MAST AND FORKS
3
Forward Forward
B Detail of A Detail of F
D
Forward Forward
C
Detail of B, C Detail of D
E
4
Forward
F
Detail of E Detail of G
5
207081 207082
Components
1. Inner mast A. Main roller E. Main roller
2. Outer mast B. Main roller F. Main roller
3. Lift chain C. Main roller G. Mast strip
4. Lift bracket D. Side roller
5. Mast support bearing cap
Diam. of
The simplex mast features two lift cylinders placed FBC15N - FBC18LN FBC20N - FBC30LN
main roller
behind the mast columns, right and left, to provide
maximum forward visibility. S 99 (3.90) 113.8 (4.48)
M 100 (3.94) 115 (4.53)
Mast strips are fitted to the top end parts of outer
mast. These strips are for backing up the inner L 101 (3.98) 116 (4.57)
mast when the mast is tilted backward. LL 102 (4.016) 117 (4.606)
Unit: mm (in.)
99759-7B110
8.1
MAST AND FORKS
6
1 207083
Sequence
1. Nut 4. Tilt socket pins
2. Forks and lift bracket 5. Tilt cylinders
3. High-pressure hose for lift cylinders 6. Mast-support bearing caps and bushing
Suggestions
Removing Lift Bracket
1. Tilt the mast forward, and lower the inner mast
all the way. Slacken the lift chains, and remove
the nuts from the anchor bolts.
2. Tilt the mast back to vertical position. Secure
the lift bracket to prevent it from falling over.
Raise the inner mast until the lift bracket
becomes free. Then, back the truck away,
leaving the lift bracket and fork assembly
standing on the floor.
207084
99759-7B110
8.2
MAST AND FORKS
Marks
207087
207085
NOTE
Weight of Components
FBC15N - FBC20N - FBC30N
FBC18LN FBC25LN FBC30LN
Gross (Simplex 520 725 830
3.3 m mast) (1150) (1600) (1830)
Unit: kg (lb)
Tilt socket
pin
207086
99759-7B110
8.3
MAST AND FORKS
Disassembly
12 10
15
3
11
10
13
9
2
16 17
2
6
6
7
6 14
1
4
5 207088
Sequence
1. Nut 10. Cylinder clamp, seat, shims, cushion, collar
and bolts
2. Forks and lift bracket
11. Bolt and shims
3. Backrest
12. Mast strip and shims
4. Main roller and shims
13. Main roller and shims
5. Main roller and shims
14. Main roller and shims
6. Side roller, bracket, and shims
15. Inner mast
7. Hose guard
16. Lift cylinders
8. Lift hose (high pressure)
(Rubber hose, T-joint and down safety valve) 17. Outer mast
9. Snap ring and chain wheel
99759-7B110
8.4
MAST AND FORKS
Suggestions
Removing Mast Strips and Main Rollers
Remove bolts 10, 11 to free lift cylinder 16. Cross
the tops of the two lift cylinders. Slide inner mast
15 toward the bottom of outer mast 17, and
remove main rollers 13, 14 and mast strips 12.
207089
99759-7B110
8.5
MAST AND FORKS
Unit: mm (in.)
207090 A = Assembly standard B = Repair or service limit
Lift Bracket
Mast Strips
1. Check the main rollers and side rollers for
smoothness of rotation. Inspect each roller for Check the mast strips for damage, wear or
wear and cracks. distortion.
2. Check the welds of the bracket for cracks.
3. Check the finger bar for bend or distortion.
Finger bar
207091
A = Assembly standard
99759-7B110
8.6
MAST AND FORKS
Reassembly
To reassemble, follow the reverse of disassembly Mast Supports
sequence and do the following steps: 1. Check mast support bushing for wear. Replace
if worn.
Adjusting Mast and Lift Bracket Clearance
2. Apply a grease to the inside surfaces and
Rollers for mast and lift bracket are available in grooves of the caps.
three sizes (diameters) for selective use. Select
3. Install mast support bushings and caps with
the size that will provide a longitudinal clearances
beveling toward the center of truck respective-
of 1 mm (0.04 in.) and less.
ly. Greasing will be facilitated if the mast is lift-
Clearance ed by placing wooden blocks under it.
Mast cap
Bushing
Clearance
Cylinder Clamps
Install each lift cylinder in place (in vertical position)
by fitting to the support, and see if there is any
1
clearance between the outer mast and cylinder.
Reduce the clearance, if any, to zero by shimming. 4 Stamped mark
207094
207093
99759-7B110
8.7
MAST AND FORKS
Forks with cracks should be removed from Check the heel of fork. Fork blade length may
service. also be reduced by wear, especially on
tapered forks and platens. Remove the forks
“Wet Test” magnetic particle inspection is gen-
from service when the blade length is no
erally preferred due to its sensitivity and the
longer adequate for the intended loads.
ease of interpreting the results.
D Toe
A
101629
99759-7B110
8.8
MAST AND FORKS
Anchor bolt
2 nut
3 nut
1 nut
102709
99759-7B110
8.9
MAST AND FORKS
F
207095
0.1 to 1.0 mm
Clearance F
(0.004 to 0.039 in.)
99759-7B110
8.10
MAST AND FORKS
Shims (a)
207156
203818
0.1 to 0.5 mm
Clearance G
(0.004 to 0.020 in.)
1 1
G1
2 2
202276
99759-7B110
8.11
MAST AND FORKS
G2
Side roller
Side Roller
G3
207158
202277
Shims
Shims
Roller 207157
Bracket
207098
99759-7B110
8.12
MAST AND FORKS
Roller Sizes
Diameter of
FBC15N - FBC18LN FBC20N - FBC30LN
main roller
H 0.1 to 0.5 mm
Clearance J
(0.004 to 0.020 in.)
207099
J
207101
99759-7B110
8.13
MAST AND FORKS
Shims
207103
NOTE
0.1 to 0.5 mm
Clearance K
(0.004 to 0.020 in.)
204889
99759-7B110
8.14
MAST AND FORKS
Shims
202961
200392
99759-7B110
8.15
MAST AND FORKS
Bolt
207105
NOTE
99759-7B110
8.16
MAST AND FORKS
200365
202983
99759-7B110
8.17
MAST AND FORKS
Service Data
Inner mast
F L
G1
G3
G2
B
F
Lift Bracket
A
C1
K
H E
J
C2
Outer mast D
207106
99759-7B110
8.18
MAST AND FORKS
Service Data
Item Truck Model FBC15N-FBC18LN FBC20N-FBC25LN FBC30N-FBC30LN
Difference in height between fork tips A 5 (0.20)
100 x 40 100 x 40 125 x 45
A
(3.9 x 1.6) (3.9 x 1.6) (4.92 x 1.8)
Forks Chains
B FBC15N FBC20N
Thickness of forks 100 x 31 100 x 38
(3.9 x 1.2) (3.9 x 1.5) 125 x 39
FBC18N FBC25N-FBC25EN (4.92 x 1.53)
100 x 33 100 x 40
(width x thickness) (3.9 x 1.3) (3.9 x 1.57)
A 318 (12.52) 381 (15.00) 508 (20.00)
Length of tilt chains (per 20 links)
B 327 (12.87) 392 (15.43) 523 (20.59)
S A 99 (3.90) 113.8 (4.48)
M A 101 (3.94) 115 (4.53)
Rollers
99759-7B110
8.19
MAST AND FORKS
Troubleshooting
Lift bracket and inner mast will a) Main rollers and side rollers having no proper clearance
not move smoothly b) Rollers involved binding on their shafts
c) Rollers damaged
d) Improper mast-to-strip clearance
Lift bracket or inner mast cocks a) Too much clearance on side rollers, or side rollers damaged
b) Lift chains unequally tensioned
c) Shim adjustments unequally made on left and right lift cylinders
(at maximum height)
Mast makes noise Rollers not rotating smoothly on their shafts, or damaged
Load drops (drifts) a) Lift cylinder packing damaged
b) Lift cylinder bore grooved
c) Control valve defective
Mast shakes entirely Mast-support bushing worn
Mast is distorted Improper loading or overload
Fork tips differ in height a) Finger bar bent
b) Forks bent
c) Distortion of mast due to off-center loading
99759-7B110
8.20
TABLE OF CONTENTS
Chapter 9: Troubleshooting
Front Axle and Reduction Differential .......................................................................................... 9.1
Brake System ............................................................................................................................... 9.2
Steering System........................................................................................................................... 9.4
Hydraulic System ......................................................................................................................... 9.6
Rear Axle ..................................................................................................................................... 9.8
Mast and Forks ............................................................................................................................ 9.9
NOTES
____________________________________________________________________________
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____________________________________________________________________________
TROUBLESHOOTING
Troubleshooting
Front Axle and Reduction Differential
Complaint Possible Cause Remedy
Gear noise comes out Teeth worn excessively or tooth contact out Readjust or replace
continuously during of adjustment in spiral bevel drive
normal cruising run
Bearing preloads too much or too little, Readjust or replace
or bearings are worn excessively
Hub bearings broken Replace
Improper tooth contact between Readjust
reduction pinion (on output shaft) and
reduction gear
Irregular noise comes Bearings associated with spiral bevel Replace
out during normal travel drive or hub bearings broken
Differential side gears have broken teeth, Replace gears or washer
or thrust washers worn
Metal piece in axle housing Clean and replace oil
Bolts securing axle shaft or differential carrier Retighten
are loose
Abnormal noise comes Fit differential gears in differential case Replace worn parts
out when turning a are out of specification due to wear
corner
Broken teeth on differential pinions or Replace defective parts
side gears, or pinions seized on spiders
Differential overheats Bearings broken due to too large a Replace bearing and readjust
preload preload
Backlash between reduction pinion Replace bearings and readjust
(on output shaft) and reduction gear preload and backlash
too small
99759-7B110
9.1
TROUBLESHOOTING
Brake System
Complaint Possible Cause Remedy
Lack of Oil leaking past primary cup in master Replace piston cup if cylinder is worn.
braking force cylinder Replace cup and fluid if the cup is
distorted.
Oil leaking past cups in wheel cylinders Replace pipe and connector and
retighten
Oil leaking from oil pipe connection Retighten
Shoe linings excessively worn Replace
Linings dirty with oil or grease Clean or replace
Pedal stroke is Air trapped in brake oil line Bleed air at master cylinder and
too large wheel cylinder
Piston cup defective in master cylinder Replace
Not enough fluid in reservoir Refill
Push rod-to-piston clearance too large Readjust
in master cylinder
Service Brakes
99759-7B110
9.2
TROUBLESHOOTING
Will not apply Parking brake cable longer than specified Check drum-to-lining clearance and,
if brake will not apply, turn adjusting
knob clockwise
Linings worn to service limit Replace shoe & lining assembly
Lining-to-drum clearance too small Readjust
Lack of brake lever operating effort Readjust to
25 to 30 kgf (55 to 66 lbf) [245 to 294 N]
99759-7B110
9.3
TROUBLESHOOTING
Steering System
Complaint Possible Cause Remedy
99759-7B110
9.4
TROUBLESHOOTING
Steering wheel turns Problem with Column loose or damaged Repair or replace
with no axle response steering column
Column splines damaged or Repair or replace
disengaged from steer gear
Air in steer gear Starved at startup Temporary
Starved from long period of non-use Temporary
No flow to steer gear Low oil level Fill as required
Ruptured hose Replace
Thermal shock damage to steer gear Replace
Blown piston seal Replace
Steering instability or Air in lines Pump sucking air at inlet Check joints
oscillation
Components or lines contain air Bleed circuit
Improper relief setting Readjust
Steering wheel turns in Lines connected to wrong cylinder ports Correct connections
wrong direction
Excessive freeplay At steering wheel Loose steering wheel nut Tighten
Damaged or worn column shaft Replace
At steered wheels Leaky cylinder seals Replace
Binding or poor Binding or misalignment between column and steer gear Readjust steer gear
centering of steering mounting bracket or
wheel replace rubber mounting
grommets
High back pressure in tank return line Clear blockages
Contamination in steer gear unit Clean unit
Steer gear locks up Contamination in steer gear unit Clean unit
Insufficient hydraulic power Check pump and power
supply
Worn or damaged steer gear or steer gear pin Replace
99759-7B110
9.5
TROUBLESHOOTING
Hydraulic System
Complaint Possible Cause Remedy
Will not lift or tilt Not enough oil in hydraulic tank Refill
Relief valve out of order because of:
1) Seized main valve Replace
2) Broken valve spring Replace relief valve
Oil pump defective Replace
Control valve switch misaligned or defective Readjust or replace
Will not lift rated Relief valve out or order because of:
load 1) Too low a relief valve setting Readjust
2) Defective plunger and poppet seat Replace relief valve
3) Weakened spring Replace relief valve
4) Damaged O-ring in valve case Replace O-ring
Oil pump defective Replace
Piston seals worn or damaged Replace
Lift speed is too low Rpm too low Adjust
Control lever installed loose, resulting in not Repair or replace
enough spool stroke
Lift and Tilt Cylinders
Check wire #25 positive or wire #26 Repair wiring or replace solenoid.
negative to the solenoid.
99759-7B110
9.7
TROUBLESHOOTING
Rear Axle
Complaint Possible Cause Remedy
Hard steering Low pump pressure Check pressure, replace pump as needed
Damaged mechanical linkage Replace
Dry mechanical linkage joints Lubricate
Mechanical joints too tight Readjust
Kingpin bearings improperly preloaded Readjust
Truck wanders Damaged or worn mechanical linkage Replace
Loose cylinder piston Replace cylinder rod
Truck drifts Damaged or worn mechanical linkage Replace
Tire diameter differs between right and left Replace tire
Erratic steering Loose cylinder piston Replace cylinder rod
Excessive freeplay Damaged or worn linkage between cylinder Replace
at steered wheels and steered wheels
Axle shimmy Excessive clearance between the kingpin and Repair or replace
its bearings
Worn or damaged hub bearing Replace
Rear tires wear Tire on one side differs in kind or brand from Replace tires
prematurely or that on the other side
unevenly
99759-7B110
9.8
TROUBLESHOOTING
Lift bracket and inner mast Main rollers and side rollers have proper clearance
do not move smoothly
Rollers involved are binding on their shafts
Rollers damaged
Improper mast-to-strip clearance
Lift bracket or inner mast Too much clearance on side rollers, or side rollers are damaged
cocks
Lift chains unequally tensioned
Shim adjustments unequally made on left and right lift cylinders
(at maximum height)
Mast makes noise Rollers not rotating smoothly on their shafts or are damaged
Load drops (drifts) Lift cylinder packing damaged
Lift cylinder bore grooved
Control valve defective
Entire mast shakes Mast-support bushing worn
Mast is distorted Improper loading or overload
Fork tips differ in height Finger bar bent
Forks bent
Distortion of mast due to off-center loading
99759-7B110
9.9
NOTES
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TABLE OF CONTENTS
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MAINTENANCE SERVICE DATA
A 0.05 (0.0020)
Face runout of axle shaft flange
B 0.5 (0.020)
Runout of axle shaft A 0.5 (0.020) max 1.0 (0.039) max
(1/2 of dial indicator reading)
B 1.0 (0.039) max 2.0 (0.079)
Preload for hub bearing 1,
A 5 to 50 (0.4 to 3.6) [0.5 to 4.9]
kgf•cm (lb•ft) [N•m]
Tightening Hub bearing lock nuts
A 20 (145) [196]
torque (outer) (2)
kgf•cm
Axle shaft bolts (3) A 8.8 (64) [86]
(lbf•ft)
[N•m] Backing plate bolts (4) A 6 (43) [59] 18.5 (134) [181]
Hubs and Wheels
Hub bolt lock nuts (5) A 6 (43) [59] 18.5 (134) [181]
6 1
4 7
203665
99759-7B110
10.1
MAINTENANCE SERVICE DATA
B 0.5 (0.020)
B 0.05 (0.0020)
6 5 4
7
10
9
3
8
2 1
203664
99759-7B110
10.2
MAINTENANCE SERVICE DATA
Transfer Case
4
2
5
209009
99759-7B110
10.3
MAINTENANCE SERVICE DATA
Rear Axle
Item Truck FBC15N - FBC18LN FBC20N - FBC30LN
Model
Oscillating angle A 3°
Toe-in A 0°
Caster A 0°
Camber A 1°
B 1.2 (0.047)
8609145
99759-7B110
10.4
MAINTENANCE SERVICE DATA
8
Rear Axle
10
11
9
6
8609146
99759-7B110
10.5
MAINTENANCE SERVICE DATA
Brake System
Truck
Item FBC15N - FBC30LN
Model
Stroke (to point where brakes start to apply) (2) A 3 to 10 (0.12 to 0.40)
Clearance between piston and push rod (3) A 0.5 to 2.7 (0.02 to 0.11)
A
Brake Pedal
Push rod
C Stop bolt
8609011
99759-7B110
10.6
MAINTENANCE SERVICE DATA
Diameter of secondary cup (lip side) (4) 20.2 ± 0.2 23.2 ± 0.25
A
(0.795 ± 0.008) (0.913 ± 0.0098)
B replace every year replace every year
Free length of return spring (5) A 46.8 (1.843) 85 (3.35)
Master Cylinder
Earlier Version
204936
Later Version 2
4
1 3 5
91246-07200
99759-7B110
10.7
MAINTENANCE SERVICE DATA
1 6 5
4 3 2
200426
99759-7B110
10.8
MAINTENANCE SERVICE DATA
Clearance between drum and lining (3) A 0.2 to 0.5 0.2 to 0.6
(one side) (0.0079 to 0.0197) (0.0079 to 0.0236)
16 ± 1.6 23 ± 2.3
Test force, kgf (lbf) [N] A (35 ± 3.5) (51 ± 5.1)
[157 ± 16] [226 ± 23]
99759-7B110
10.9
MAINTENANCE SERVICE DATA
1
4
2 6
3
Secondary spring 4
5
Free length
203588
Applied
F
Parking Brake
Released
209790
99759-7B110
10.10
MAINTENANCE SERVICE DATA
Steering System
Truck FBC15N - FBC18LN FBC20N - FBC30LN
Item
Model
99759-7B110
10.11
MAINTENANCE SERVICE DATA
Steering System
Minimum test pressure for leaks, A 107 (1522) [10,500] 163 (2320) [16,000]
kgf•cm2 (psi) [kPa]
torque, kgf•cm,
(lbf•ft) [N•m] Mounting bolts (2) A 17.9 (130) [176] 26.7 (193) [262]
8609149
99759-7B110
10.12
MAINTENANCE SERVICE DATA
Hydraulic System
Item Truck FBC15N FBC18N FBC18LN FBC20N FBC25N FBC25EN FBC25LN FBC30N -
Model FBC30LN
48 volt lift speed (rated load) mm/sec (fpm) A .34 (67) .32 (64) .47 (93) .40 (78) .38 (74) .32 (64)
Lowering speed (rated load) mm/sec (fpm) A .58 (115) .57 (113) .59 (116) .52 (102)
Main relief valve setting, kgf•cm2, (psi) [kPa] A 197±kgf/cm2 (2630 ± 50 psi) [19650 ± 34 kPa]
99759-7B110
10.13
MAINTENANCE SERVICE DATA
3 2 1
4
207073
Return
Tightening torque
Filter
A 49 ± 10 (5 ± 1) [36 ± 7.2]
N•m (kgf•m) [lbf•ft]
99759-7B110
10.14
MAINTENANCE SERVICE DATA
[Socket] thread diameter (6) A M24 x 1.5 M27 x 1.5 M30 x 1.5
Tightening Socket bolt (7) A 127 to 152 (13 to 15.5) [94 to 112]
torque, N•m
(kgf•m) [lbf•ft] 127 ± 9.8 235 ± 19.6 39.2 ± 25
Self-locking nut (8) A (13 ± 1.0) (24 ± 2.0) (40 ± 2.5)
[94 ± 7.2] [174 ± 14.5] [289 ± 18.1]
7 5 1 2 8 207033
99759-7B110
10.15
MAINTENANCE SERVICE DATA
FBC15N FBC20N
100 x 31 100 x 38
B (3.9 x 1.2) (3.9 x 1.5) 125 X 39
FBC18N - FBC18LN FBC25N/FBC25EN/FBC25LN (4.92 x 1.53)
100 x 33 100 x 40
(width x thickness) (3.9 x 1.3) (3.9 X 1.57)
A 318 (12.52) 381 (15.00) 508 (20.00)
Length of tilt chains (per 20 links)
B 327 (12.87) 392 (15.43) 523 (20.59)
S A 99 (3.90) 113.8 (4.48)
Rollers
F Inner mast
L
G1
G3
G2
Mast and Lift Bracket/Later Version
B
F
Lift Bracket
A C1
K
H
E
J
C2
D
Outer mast
207106
Tightening Mast support bolts A 7.5 (54) [74] 18.2 (132) [178]
torque, kgf•m
(lbf•ft) [N•m] Chain wheel support
A 9.9 (72) [97]
bolts
99759-7B110
10.17
MAINTENANCE SERVICE DATA
mm in. mm in. kgf·m (lbf·ft) [N·m] mm in. mm in. kgf·m (lbf·ft) [N·m]
6 0.24 1 0.04 0.6 4.3 5.9 6 0.24 1 0.04 0.7 5.1 6.9
8 0.32 1.25 0.05 1.4 10.1 13.7 8 0.32 1.25 0.05 1.7 12.3 16.7
10 0.39 1.25 0.05 2.9 21.0 28.4 10 0.39 1.25 0.05 3.4 24.6 33.3
12 0.47 1.25 0.05 5.2 37.6 51.0 12 0.47 1.25 0.05 6.1 44.1 59.8
14 0.55 1.5 0.06 8.4 60.8 82.4 14 0.55 1.5 0.06 9.9 71.6 97.1
16 0.63 1.5 0.06 12.6 91.1 123.6 16 0.63 1.5 0.06 14.8 107.0 145.1
18 0.71 1.5 0.06 18.2 131.6 178.5 18 0.71 1.5 0.06 21.4 154.8 209.9
20 0.79 1.5 0.06 25.2 182.3 247.1 20 0.79 1.5 0.06 29.7 214.8 291.3
22 0.87 1.5 0.06 33.4 241.6 327.5 22 0.87 1.5 0.06 39.3 284.3 385.4
24 0.95 1.5 0.06 42.2 305.2 413.8 24 0.95 1.5 0.06 49.7 359.5 487.4
Note
1. These charts give the torques for standard bolts and nuts.
2. The tolerance for these torques is ± 10%.
3. Unless otherwise specified, use these torques.
4. These torques are for “dry” conditions.
Coarse Thread – With Spring Washer Coarse Thread – Without Spring Washer
With Spring Washer Without Spring Washer
mm in. mm in. kgf·m (lbf·ft) [N·m] mm in. mm in. kgf·m (lbf·ft) [N·m]
10 0.39 1.5 0.06 2.8 20.3 27.5 10 0.39 1.5 0.06 3.3 23.9 32.4
Metric Coarse Thread
12 0.47 1.75 0.07 4.9 35.4 48.1 12 0.47 1.75 0.07 5.8 42.0 56.9
14 0.55 2.0 0.08 8.1 58.6 79.4 14 0.55 2.0 0.08 9.5 68.7 93.2
16 0.63 2.0 0.08 12.1 87.5 118.7 16 0.63 2.0 0.08 14.2 102.7 139.3
18 0.71 2.5 0.10 16.8 121.5 164.8 18 0.71 2.5 0.10 19.8 143.2 194.2
20 0.79 2.5 0.10 23.5 170.0 230.5 20 0.79 2.5 0.10 27.7 200.4 271.6
22 0.87 2.5 0.10 31.5 227.8 308.9 22 0.87 2.5 0.10 37.0 267.6 362.8
24 0.95 3.0 0.12 40.5 292.9 397.2 24 0.95 3.0 0.12 47.7 345.0 467.8
99759-7B110
10.18
MAINTENANCE SERVICE DATA
Tightening Torques for Standard Bolts and Nuts with Standard Threads
Coarse Thread – Inches
Maintenance Chart
Use the service chart to determine servicing intervals. Calendar intervals shown (weekly, monthly, etc.)
may be used instead of service meter intervals if they provide more convenient servicing schedules and
approximate the indicated service meter reading. Recommended service should always be performed at
the interval that occurs first.
Perform service on items at multiples of the original requirement. For example, at every 1200 hours or 6
months, also service those items listed under every 200 hours or monthly, every 50 hours or weekly and
daily (pre-start).
● = Check or clean
★ = Change or adjust
R = Replace
Maintenance Intervals
Every 50 hours
Inspection Point How to Check Service Data
or 6 months
or monthly
or weekly
or 1 year
Motors Bearing lubrication, damage Visual ● ● Lubricate
Operation Test ● ● ● ● ●
Maintenance Intervals
Every 50 hours or
Daily (pre-start)
6 months
monthly
weekly
1 year
89 ± 3 mm
Brake pedal Height of pedal above floor Scale ● ● ● ● ● (3.5 ± 0.12 in.)
Stroke to point where brakes Scale ● ● ● ● ● 3 to 10 mm
start applying (0.12 to 0.4 in.)
Parking brake Lever lock position:
Performance Test/spring 4° - 5°
balancer ● ● ● ● ●
Operating effort:
55–66 kgf
(25–30 lbf)
[245–294 N]
Brake hoses Fluid leaks, damage or Visual ● ● ● ● ●
and pipes installation
Brake fluid Level in reservoir Visual ● ● ● ● ★ 103cc (7.9 cu. in.)
Wheel brakes Master cylinder and wheel Overhaul/
cylinders—operation, wear and Replace ★
damage
Brake clutch/inching pedal rod Visual/wrench ●
Brake master cylinder hoses & R
rubber parts
Service brake fluid R
Brake wheel cylinder rubber parts R
FBC20N-FBC30LN
0.2 to 0.6mm
(0.01 to 0.02)
FBC15N-FBC18LN
Sliding surfaces of shoes and Disassemble/ ● 2.5mm (0.10 in.)
wear of lining calipers
FBC20N-FBC30LN
3.0mm (0.12 in.)
Service Limit:
FBC15N - FBC18LN
254 + 0 0.13 mm
Drum—wear or damage Visual scale ● (10.00 + 0 0.0051 in.)
FBC20N-FBC30LN
310 + 0 0.13 mm
(12.20 + 0 0.0051 in.)
99759-7B110
10.21
MAINTENANCE SERVICE DATA
Maintenance Intervals
Every 50 hours or
Daily (pre-start)
6 months
monthly
weekly
1 year
Backing plates Distortion, cracks, or damage Dye check ●
Fitting cables– Visual/scale ●
damage and length
Ratchet–wear or damage Visual ●
Front axle Cracks, distortion, Dye check/ ●
or other defects visual
Front wheel bearings–preload Spring balancer ● Hub bearing preload
5 to 50 kgf
(0.4 to 3.6 lbf•ft)
[0.5 to 4.9 N•m]
Fore-aft play Test ●
Cracks, distortion, or Visual ●
other defects
Differential Oil level and oil leaks Visual ● ● ● FBC15N - FBC25EN
5.7 liters (1.5 U.S. gal)
FBC25LN - FBC30LN
6.1 liters (1.6 U.S. gal)
99759-7B110
10.22
MAINTENANCE SERVICE DATA
Maintenance Intervals
or 6 months
or monthly
or weekly
or 1 year
Hydraulic tank Oil level and contamination Visual ● ● ● ● ★
Strainer—clogging Visual ★
Return filter—clogging Visual ★
Hydraulic pump Oil leaks or abnormal noise Visual / listen ● ● ●
Control valve Oil leaks Visual ● ● ● ● ●
185 kgf/cm2
Main relief valve setting Pressure gauge ● (2631 psi)
[18,142 kPa]
Auxiliary relief valve setting Pressure gauge ● 158±5 kgf/cm2
2250±71psi
15,513 ± 490 kpa
Overload relief setting (optional) Pressure gauge ●
Control levers and links—rattle Test ● ● ● ● ●
Lift cylinders Cracks, distortion, or Visual ● ● ● ● ●
other defects
● ● ● ● ● FBC15N - FBC25EN
Rod drift (rated load) Visual/watch/ 50 mm (2.0 in.)/15 min
scale FBC25LN - FBC30LN
40 mm (1.6 in.)/15 min
Attachment ● ● ● ● ●
Mounting bolts—tightness Wrench ● ● ●
Oil Leaks Visual ● ● ● ● ●
99759-7B110
10.23
MAINTENANCE SERVICE DATA
Maintenance Intervals
hours or 1 year
Inspection Point How to Check Service Data
or 6 months
Every 2400
or monthly
or weekly
Tilt cylinders Cracks, distortion, Visual ● ● ● ● ●
or other defects
Oil leaks Visual ● ● ● ● ●
Forward rod drift (rated load) Watch/scale ● ● ● FBC15N - FBC18LN
22 mm (0.9 in.)/15 min
FBC20N - FBC25LN
20 mm (0.8 in.)/15 min
FBC30N - FBC30LN
15 mm (0.6 in.)/15 min
Mounts—rattle or damage Visual/free ● ● ● ● ●
Rod socket nut—tightness Torque wrench ● ● ● ● ● FBC15N - FBC18LN
15 kgf·m
(108 lbf•ft)
[147 N•m]
FBC20N - FBC30LN
40 kgf·m
(289 lbf·ft)
[392 N·m]
Piping Oil leaks Visual ● ● ● ● ●
Rubber hoses: damage Visual ● ● ●
Hose reels and swivel joint— Visual ● ● ●
distortion or other defects
Mast and Cracks, distortion, Visual/ ● ● ● ● ●
lift bracket or other defects dye check
Mast supports—rattle or ● ● ●
damage
Main rollers—clearance, Feeler gauge/ ● ● ● Each roller to
damage dial gauge mast clearance
(at max. height):
0.1 to 0.5 mm
(0.004 to 0.020 in.)
99759-7B110
10.24
MAINTENANCE SERVICE DATA
Maintenance Intervals
6 months
or 1 year
monthly
weekly
Lift chains and Length of lift chains (20 links) Scale ● FBC15N - FBC18LN
chain wheels 318 mm (12.5 in.)
FBC20N - FBC25LN
381 mm (15.0 in.)
FBC30N - FBC30LN
508 mm (20.0 in.)
99759-7B110
10.25
MAINTENANCE SERVICE DATA
1 ★
Rubber parts for brake Replace ● ●
master cylinder
2 ★
Rubber parts for brake Replace ● ●
wheel cylinders
3 ★
Hydraulic hoses Replace ● ●
4 ★
Hoses for power steering Replace ●
5 ★
Rubber parts for Replace ●
steering cylinder
6 ★
Lift chains Replace ●
7 Hydraulic tank return filter Replace ● ● ● ●
8 Drum to lining clearance Check or replace ● ●
9 Motor brushes Check or replace ● ●
★
Indicates important safety-related parts
99759-7B110
10.26
99759-7B110
LUBRICATION AND MAINTENANCE CHART BE SURE TO PERFORM SERVICE ITEMS QUOTED BELOW
CHECK LUBRICATE
EVERY 50 HR. OR WEEKLY
Lubrication Chart
NOTE: REDUCE SERVICING INTERVALS IN DUSTY OR SEVERE CONDITIONS. REFER TO OPERATION MANUAL 97182-12900
MAINTENANCE SERVICE DATA
10.27
10.28
◆
Wheel bearings NLGI No. 2 grade multipurpose type (lithium base), consistency: 265 - 295
Grease
MAINTENANCE SERVICE DATA
Chassis NLGI No. 1 grade multipurpose type (lithium base), consistency: 310 - 340
• Avoid mixing lubricants. In some cases, different brands of lubricants are not compatible with each other and deteriorate when mixed. It is best to stick
with the same brand at successive service intervals.
Fuel and Lubricant Specifications
Shell Shell Spirax EP90 Retinax A No. 1 Retinax A No. 2 Tellus oil 22 Tellus oil T-32
Castrol Castrol Hypoy Castrol LM Grease Castrol Spheerol API Castrol Hyspin Castrol Hyspin
AWS32 AWS68
■ Brands of oil are subject to change without notice.
■ When you buy oil, select recommended brands and check specifications.
99759-7B110
MAINTENANCE SERVICE DATA
99759-7B110
10.29
MAINTENANCE SERVICE DATA
13 05312-20650 ● — —
05312-20850 — — ●
99759-7B110
10.30
MAINTENANCE SERVICE DATA
164
95 17
250 10
22
155 91268-00300
91268-00701 91868-02100
3 4
64309-17701 91268-00800
5 6
90
03703-59001 91648-00300
7 8
64309-40400 64309-15411
99759-7B110
10.31
MAINTENANCE SERVICE DATA
9 10
64309-15412 64309-15413
11 12
M12 X 1.25
M8 X 1.25
ø32
ø35
45 30 45
55
91268-10600 91268-01600
13 14
Flame-hardened Hv >500,
depth 2mm (0.08 in.) 05312-20650
05312-20750
05312-20850 F4540-06300
15 16
97157-00100 64309-40100
99759-7B110
10.32
MAINTENANCE SERVICE DATA
17 18
MH061017 6V3965
19 20
97E67-00100 97E67-00200
21
97E67-00500
99759-7B110
10.33
MAINTENANCE SERVICE DATA
Inspection Guide
Check For (item or defect) How
DEFECTS
d) Corrosion Visually
8609151
8609152
99759-7B110
10.34
MAINTENANCE SERVICE DATA
8609154
8609155
8609156
i) Damaged seal (caused by
improper use of tools) Visually
8609157
8609158
99759-7B110
10.35
MAINTENANCE SERVICE DATA
8609159
8609160
DEFECTS
Nicks, burrs, or other flaws on bearing surface Hold bushing toward a light and look
through bore
Fasteners DEFECTS
Gears ITEMS
DEFECTS
99759-7B110
10.36
MAINTENANCE SERVICE DATA
e) Pitting Visually
f) Spalling Visually
99759-7B110
10.37
MAINTENANCE SERVICE DATA
Keys and keyways Wear on sides making parts not fit tightly Examine by placing
Roller chains and a) Wear on pins, bushings, rollers, and plates in Visually
sprockets each link tending to increase in pitch.
Chain load
Sprocket rotation
New Old
8609189
Fit
DEFECTS
8609170
99759-7B110
10.38
MAINTENANCE SERVICE DATA
b) Squareness
8609171
d) Test force
DEFECTS
8609172
8609173
99759-7B110
10.39